This morning I started it and let it run but I forgot to unplug the block heater while it warmed up. When I went out after 10 minutes later, unplugged the block heater and got in. As I backed out of the drive, it sputtered and died. no re start. Cranks and cranks but won't fire. Did I fry something electrical by leaving the block heater plugged in while the truck was running?

I pulled the fuel filter, installed a new one. The fuel was not gelled at all, though it has been below 0 the last couple of nights. Where do I start?

 

You didn't fry anything by leaving the block heater plugged in. It's a stand alone system and is a dead short circuit. I did the same thing this morning, on purpose, and had no problem.

Once a diesel is running it should stay running unless there is an interruption in fuel, or air entering the system.

Check your FSS solenoid. Sometimes they just go bad. Check to make sure you have 12V ign. going to the FSS. If that checks out then pull the FSS and remove the plunger and spring and re-install. If it fires then you know this was your problem. And you will need to use the shut down lever on the side of the IP if it starts running with the FSS gutted.

If after all this it still doesn't start then there is a good chance you have air getting into the system and it will need to be bled to start. But then you will need to find the leak.

 

Glad nothing got fried. I didn't think it would be an issue but I thought I'd ask. I just checked the large wire at the FSS, it has 12v ignition power. I'll pull that solenoid and check the plunger tomorrow. Too cold out there tonight, too lazy to push it around back to the heated shop.

 

I would use a jumper wire and apply 12v to the fss and see if I can hear it clicking before I would pull it out. did it die like you shut the key off or did it spit and sputter before it died?

 

Hey Bill...I re-read his first post and it seems it sputtered and died. So might not be the FSS, but a fuel/air related issue.

 

I'll try the jumper wire in the morning and then check all the fuel lines and fittings for leaks.

 

I tried putting a 12 volt jumper wire to the shutoff solenoid, it seems to be doing its job. I inspected all of the fuel lines from the tank to the mechanical pump on the side of the motor, they all look clean and dry. I installed a new water separator, filled it with fuel, still no start. When I pump the little primer lever, nothing seems to be happening. I cracked what looked like a bleeder just above the water separator housing (the one on the line that goes to the injector pump) and primed it for a couple minutes. No fuel came out. Any more suggestions?

I'm planning on taking this thing on a 2000 mile road trip in about 3 weeks, towing an offroad buggy over the rockies from Denver to Cali and back. Any other things that I should be checking would be appreciated. I've had this thing 6 years and NEVER had it not start before. Very frustrating.

 

Make sure the cam is in the right position when you prime the lift pump, or the pump lever wont do anything.

 

might need to bleed injectors too.

 

Pardon my ignorance but what position does the cam need to be in for the lift pump to prime properly? I thought it would prime anytime. Do I need to rotate the engine by hand and engage the timing pin (same one used in adjusting the valves) that is hidden behind the injector pump?

Whatever it is I'm glad it happened in my driveway. I'm going on a 2000 mile trip towing my buggy, Denver to California, in a couple weeks. Any other 'pre flight checks' you guys would recommend before the trip?

 

Just turn the engine by hand little by little and try priming it. You shouldent havta engage the timing pin i dont think. Mine wouldent prime one time and i just bumped the engine over with the key and tried again and it primed.

 

GOT IT STARTED AND RUNNING! Thanks for all the good advice. Once I bumped the motor over a couple times I could feel when the lift pump primer lever was doing its thing. Got fuel to the inj pump, bled it from the injectors and vroom.

 

BUT, what made it do this? What actually was the problem ?

 

Sounds like Air in the system to me. But yeah would definitely like to know why it happened.

I'd keep the equipment needed to prime and bleed the system again in the truck. Especially if it dies on your trip.